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ZENER 8000-V Installation Manual

IM00165

Loading an Application

Follow the diagram below to load an application. E.g. Loading the “

4 Speed Sel. -00

”

application.

A00 DEFAULTS

0.0Hz 0.0kW
0% 0.0A

Application:
< none >

Loading...
4 Speed Sel. -00

Application:
4 Speed Sel. -00

4 Speed Sel. -00
set up (default)

ESC



EXIT



DOWN

(several times)



ENTER





Load Factory
Defaults?



ENTER





ENTER





DOWN

several times to

find the desired

application



Begin at a

run display

The application is loaded. Press

Enter

to view application parameters.

Summary of Contents for 8000-V

Page 1: ...ZENER VARIDRIVE SOLUTIONS ZENER 8000 V Installation Manual Document IM00165 Printed 27 February 2019...

Page 2: ...e program ensures that every ZENER 8000 V manufactured has proven to operate correctly in the production test bay before dispatch SAFETY Your ZENER 8000 V must be applied installed and operated in a s...

Page 3: ...ting 10 Panel Cut out 10 Installation of Remote Console 10 ZENER 8000 V Power wiring 11 AC line overcurrent protection device 11 Coordination of supply circuit protection and switchgear 11 Cable sizes...

Page 4: ...lectromagnetic Compatibility EMC 22 Installation practices and EMC 22 Screened power cables and alternative materials 23 EIA RS 485 Communications Wiring 24 Best practice 24 Terminating resistors 25 G...

Page 5: ...dditional detailed information 45 Communications Protocols 45 Transport considerations 45 Maintenance considerations 45 Spare parts 45 Packing for transport 45 Display Messages 46 Fault Messages 46 St...

Page 6: ...Contents iv IM00165...

Page 7: ...d in any aspect of installation adjustment or maintenance Your ZENER 8000 V must be applied and installed by suitably qualified and experienced personnel in accordance with this manual good engineerin...

Page 8: ...proper and safe operation Do not use the braking functions of the product for safety purposes The ZENER 8000 V has features that may be used to cause an automatic restart in certain circumstances The...

Page 9: ...0 V where it is subject to heating by direct sunlight or other heat radiating sources ZENER 8000 V must be mounted vertically No other mounting orientation is acceptable The thermal design of the user...

Page 10: ...LATE Opening 94mm x 54mm M1 TERMINAL M2 TERMINAL M3 TERMINAL L1 TERMINAL L2 TERMINAL L3 TERMINAL V1 Module dimensions ZENER 8000 V Mechanical Installation Information Each ZENER 8000 V system consists...

Page 11: ...420 25mm x 25mm x 3mm ANGLE M6 TAPPED HOLE for mounting clamp M8 TAPPED HOLES M6 TAPPED HOLE for mounting clamp M6 TAPPED HOLE for mounting clamp M6 TAPPED HOLE for mounting clamp M6 TAPPED HOLE for...

Page 12: ...n Sheet 2 150 150 150 1018 380 380 150 AIR EXHAUST This area must be kept clear AIR INTAKE This area must be kept clear 150 150 1018 INVERTER HEATSINK This area must be kept clear CUSTOMER S PANEL CUS...

Page 13: ...mm 28 mm 104 mm BOTTOM GLAND PLATE Opening 94mm x 54mm BOTTOM GLAND PLATE Opening 94mm x 54mm TOP GLAND PLATE Opening 94mm x 54mm COOLING FAN ASSEMBLY Allow access for removal L1 TERMINAL L2 TERMINAL...

Page 14: ...0 mm 130 mm 130 mm 10 mm 758 mm 718 mm 611 mm 651 mm 25mm x 25mm x 3mm ANGLE CUTOUT 131 mm 20 mm 14 mm 20 mm M6 TAPPED HOLE for mounting clamp M6 TAPPED HOLE for mounting clamp M6 TAPPED HOLE for moun...

Page 15: ...USTOMER S PANEL 277 mm AIRFLOW i For installations with inverter modules mounted side by side the minimum mounting pitch horizontally is 751mm Systems that use parallel connected modules ratings 200A...

Page 16: ...commodate the depth of the remote console Cut out the panel as shown in the drawing below Installation of Remote Console The console is secured in position by the rear clamps Do not over tighten An Ea...

Page 17: ...itical factor in determining the injury risk extent of physical damage and consequently the time and expense involved in repair The let through energy may be accessed in terms of the I2 t time integra...

Page 18: ...sure by the installer to indicate the dual supply arrangement in accordance with your local electrical code and other safety requirements A means of isolating the second electrical supply source will...

Page 19: ...etails 3 Phase AC supply Input line reactor Output line reactors Important notes Input and output line reactor terminals should not be used to terminate field wiring Customer s field wiring terminals...

Page 20: ...t earth bonding wire of not less than 6mm2 is required between adjacent inverter modules for functional purposes This is in addition to any earth wire provided for safety purposes To ensure proper cur...

Page 21: ...trol Cable Diagram Module viewed from below Control Connector Identification Connector 3 RJ 45 for Cat 5 cable Connector 1 25 pin female Connector 2 25 pin male Control Interconnection for Parallel Un...

Page 22: ...nd should not be considered in any way to represent an alternative to appropriate professional engineering advice A general explanation of IT and TN electrical distribution earthing systems is provide...

Page 23: ...quipment current rating however the nature path and magnitude needs to be considered in the design of a safe and reliable installation There is a capacitive current path to any conductor in the vicini...

Page 24: ...g Ipk Instantaneous peak value of the leakage current Possible consideration of the potential to overload the input circuitry of instrumentation or disrupt operation in other ways Depends on the desig...

Page 25: ...It is unlikely that a single evaluation method will meet all requirements Contact Zener for additional information Earth leakage monitoring instruments devices The following notes may be of assistance...

Page 26: ...portional to the voltage applied so the capacitive leakage currents in 1000V equipment are in principle about 2 5 times higher than those in 415V systems This factor is independent of the IT or TN sup...

Page 27: ...n pilot earth circuits be used in cables associated with 1000V VFDs There is no inherent reason that prevents the use of pilot earth AKA earth check systems however the electrical environment inside a...

Page 28: ...n between the inverter and motor This reduces the opportunity for high frequency currents to flow in incidental paths between inverter and motor Incidental paths may involve cables of other circuits o...

Page 29: ...formance of these materials is well understood by analysis from basic principles Specific data has been reported in reputable engineering research journals These materials generally offer very high pe...

Page 30: ...n the limits specified by the standard The Shield is connected to earth ground at one end3 only and provides protection against capacitive coupling to nearby cables and other electrical noise sources...

Page 31: ...acent to power cabling and wiring If not possible utilise the best separation of communication cabling and power cabling Communication cables should cross power cables at right angles The EIA RS 485 s...

Page 32: ...ZENER 8000 V Installation Manual _ 26 IM00165 Extended Features Option Wiring...

Page 33: ...priate Control Wiring Diagram or follow a quick setup The ZENER 8000 V is now ready to run Before applying power ensure that rotation of the motor shaft will not cause injury or damage After applying...

Page 34: ...s variable PV with its units and the second line displays set point variable SV expressed with the same units PID Meter Display The top line displays the operating output frequency and process variabl...

Page 35: ...pressing the FWD button The motor will accelerate to this speed The speed reference is decreased by pressing the REV button The motor will decelerate to this speed The ZENER 8000 V may be started in r...

Page 36: ...times in a row to return back to the operation displays After applying power it is recommended that you at least go through the B00 MOTOR C00 PERFORMANCE and G00 INPUT OUTPUT menus to set up the ZENER...

Page 37: ...information Once an application is installed it becomes the first menu visible from the operational displays as shown below The diagram above is an example of the installed application 4 Speed Sel 00...

Page 38: ...plication A00 DEFAULTS 0 0Hz 0 0kW 0 0 0A Application none Loading 4 Speed Sel 00 Application 4 Speed Sel 00 4 Speed Sel 00 set up default ESC EXIT DOWN several times ENTER Load Factory Defaults ENTER...

Page 39: ...to access the Application user menu Changing an Application There are 2 steps necessary to change an application 1 Restore factory defaults a Go to the Load Factory Defaults menu press Enter b Follow...

Page 40: ...ly The ZENER 8000 V control terminals can be configured on an individual terminal basis to suit a wide variety of applications This provides enormous flexibility Factory default settings The factory d...

Page 41: ...way to map a finite set of physical digital inputs to the internal set of input functions The simplest way to configure digital inputs is to utilise one of the pre existing configurations from the G0...

Page 42: ...om I00 FWD LATCH D3 4 D2 3 EN 6 D2 3 D2 3 OFF D2 3 Not specific Refer to each functional assignment I01 REV LATCH OFF OFF OFF D3 4 OFF OFF OFF I02 STOP D2 3 D1 2 EN 6 D1 2 D1 2 OFF D1 2 I03 FWD OFF OF...

Page 43: ...ref 9 IN 10 IN 11 A 12 15 16 18 17 RL1 RL2 Control Board Terminals RS 485 EIA 485 Serial Communications B 13 C 14 8 9 10 11 Input reference source Run Stop Reset Local Remote Optional Optional Output...

Page 44: ...front panel console In remote stop start is controlled from the terminal strip The source of the speed reference in both modes may be independently configured to come from a wide variety of sources i...

Page 45: ...the Reference Manual for more information Preset speed This provides a single fixed speed Go to the F00 REFERENCES menu and select F01 REMOTE REF Press Enter Use the arrows to display the options Pres...

Page 46: ...ault G00 INPUT OUTPUT G03 RL1 G030 RL1 Signal RUN default G04 Rl2 G040 RL2 Signal TRIP default B00 MOTOR B01 MOTOR VOLTS Motor nameplate voltage B02 MOTOR AMPS Motor nameplate amps B03 MOTOR HZ Motor...

Page 47: ...ZENER 8000 V features and functions remain available Expected Wiring One Time Installation Application choice Load the Machine JOG 00 application Refer to Loading an Application page 32 Application P...

Page 48: ...e console to increase the speed beyond the minimum speed Release the UP push button at the desired output frequency Press and hold the DOWN push button on the console to decrease the output speed Rele...

Page 49: ...eter o Press UP or DOWN to adjust the value ENTER to accept the value or ESC to abandon changes Application Parameters This screen displays the preset pressure reference required for the pump This scr...

Page 50: ...smaller value will reduce steady state error but may increase overshoots In closed loop operation the pressure is not stable Go to H00 PID Control PID A increase the H01 PROP BAND or decrease H03 Dif...

Page 51: ...incorporate heatsink cooling fans that are replaceable as modular assembly accessible from the clean switchboard interior side of the equipment Please ensure that other equipment located in the switch...

Page 52: ...missing and motor operation will be impaired BRAKE SHORT Either an Over Current or a Ground Fault has been detected on the dynamic brake resistor terminals EARTH FAULT An earth leakage fault has been...

Page 53: ...nsole display The status messages include Status Message Description U MODE 1 Remote user mode 1 message Refer to F0122 MODE1 text for message customisation U MODE 2 Remote user mode 2 message Refer t...

Page 54: ...mode PID OFF The PID block is ready to operate but no run command is given FILLING The pipe fill function is activated and pipe filling is underway PID A O N The PID A block is operating and the ZENE...

Page 55: ...rs Electromechanical contactors and motor starters thermal overload specification class 10A Local Controls Console buttons Up Down Enter Escape Stop Reset Terminal Strip Functions Digital Inputs 5V an...

Page 56: ...I2t cnr Hz 2 to 200Hz Drive Stopping Ramp to stop Coast to stop Auto Restart Number of restarts 0 to 20 Reset time 0 1 to 20 minutes References Analog Input Console Reference Preset Motorised Potentio...

Page 57: ...when UP button on the Console is pressed Enable signal is not active Check that the EN terminal is connected to 5V Check that the ENABLED message is displayed ZENER 8000 V is in REMOTE Check that if...

Page 58: ...the actual load is within the motor s capacity at the required speed Motor shaft jammed Check the mechanical drive system Fault in motor or motor wiring Check that motor is wired correctly Incorrect m...

Page 59: ...and ambient temperature rating Motor is unstable SLIP COMP is set too high Check that MOTOR NAMEPLATE RPM setting is equal to the motor rated speed Check that NAMEPLATE CURRENT setting is equal to th...

Page 60: ...V E074 Hi Radiance CONSOLE E075 Vmp Volts 550V E076 Display var PV A E077 Lo Solar t 0 secs Parameter User Default E078 SFC time 1 sec E079 SFC Ext sel OFF F010 REMOTE REF AI 10 11 F011 REMOTE Inpt6 s...

Page 61: ...ard T1 IN1 2 3 m0 7 IN LLLLLLHL T1 IN1 2 3 m0 7 Reset LHLHLHLH G073 T2 Interval 1 secs G074 T2 mode Delay ON Parameter User Default G0750 T2 Input 1 OFF G0751 T2 Input 2 OFF G0752 T2 Reset OFF G0753 T...

Page 62: ...put OFF G252 Alarm delay 1 sec G253 Alarm text UA3 ALARM G260 Alarm mode ALWAYS G261 Alarm input OFF G262 Alarm delay 1 sec G263 Alarm text UA4 ALARM Parameter User Default G270 Warn mode ALWAYS G271...

Page 63: ...0 JOGREV OFF I11 REMOTE D4 5 I200 LB1 Input 1 OFF I201 LB1 Input 2 OFF I202 LB1 Input 3 OFF I203 LB1 m0 7 LLLLLLLL I210 LB2 Input 1 OFF I211 LB2 Input 2 OFF I212 LB2 Input 3 OFF I213 LB2 m0 7 LLLLLLLL...

Page 64: ...in some way There are a number of different arrangements in use Two systems in common use are TN system In this system the neutral conductor of the supply is directly connected to an earth electrode I...

Page 65: ...antial proportion of electrical faults particularly associated with cables which might begin as earth faults and otherwise progress to a major high current faults with considerable potential for perso...

Page 66: ...nt of emission and immunity levels to achieve functional coexistence between various items of equipment in a given environment EN The enable input on the ZENER 8000 V ESO Essential Services Override A...

Page 67: ...e motor speed can increase or decrease Remote Operation of the ZENER 8000 V via connections made to the control board terminal strip RMS Technically Root Mean Square A method of measuring an AC voltag...

Page 68: ...ZENER 8000 V Installation Manual _ 62 IM00165...

Page 69: ...ZENER 8000 V Installation Manual IM00165 63...

Page 70: ...au Zener Electric Pty Ltd 2019 IM00165 27th February 2019 ZENER ELECTRIC PTY LIMITED ACN 001 595 428 366 Horsley Rd Milperra NSW 2214 Australia PO Box 347 Milperra NSW 2144 Australia T 61 2 97953600...

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